Stone slab manufacturing methods and systems

ABSTRACT

This document describes systems and processes manufacturing and distributing stone slabs, such as including distributing a stone slab and a slab image file associated with the stone slab. The slab image file may include an image and associated information to facilitate one or more operations related to the stone slab.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Application Ser. No.62/270,236, filed on Dec. 21, 2015, which is fully incorporated hereinby reference.

TECHNICAL FIELD

This document describes processes and systems for manufacturing andproviding a stone slab in conjunction with, for example, a digital imagerepresentation of the stone slab.

BACKGROUND

Stone slabs are a commonly used building material. Granite, marble,soapstone, and other quarried stones are often selected for use ascountertops, tables and floors. Engineered stone slabs may be formedfrom a man-made combination of materials that can provide improvedaesthetic characteristics and stain-resistant or heat-resistantproperties. Quarried and engineered stone slabs are typically cut to adesired size and shape prior to installation.

Digital representations of stone slabs may be used to facilitate orautomate selection and cutting. For example, digital representations ofstone slabs have been used by slab fabricators and installers tofacilitate modeling of a project and/or cutting stone slabs as neededfor a particular installation.

SUMMARY

Some embodiments described herein include systems and methods ofmanufacturing and distributing stone slabs suitable for use in living orworking spaces (e.g., along a countertop, table, floor, or the like).Exemplary systems and methods may include generating a high resolutionimage and metadata related to a stone slab at the time of manufacturethat can be used in subsequent fabrication, quality assurance, or otheractivities, and providing the image and stone slab to a remote party.The image and associated metadata may also facilitate efficient and/orautomated selection and matching of stone slabs without requiringphysical manipulation of a stone slab and with limited human review ofmultiple images.

Particular embodiments described herein include an exemplary method ofmanufacturing and distributing stone slabs and corresponding images ofthe stone slabs. The method may include manufacturing a stone slab, andassigning a unique identifier associated with the stone slab. The methodmay also include providing a slab image file associated with the stoneslab to a remote party. The slab image file may include a highresolution image of the stone slab and image metadata indicative ofcharacteristics of the stone slab, and the image metadata of the slabimage file may include the unique identifier and a predetermineddimensional relationship. For example, the predetermined dimensionalrelationship provided by the slab image file may include a ratio ofstone slab unit length per image pixel, and optionally, the ratio may besubstantially consistent at any location of the image.

In some implementations, the method can optionally include one or moreof the following features. The method may include providing the stoneslab to the remote party. The method may include storing the slab imagefile in a database. The step of providing the slab image file to theremote party may include granting the remote party access to thedatabase. The method may include assigning the stone slab to a remoteparty before the step of providing the slab image file to the remoteparty. The image metadata may include a color characteristic of thestone slab and the step of assigning the stone slab to a remote partymay include assigning the stone slab based at least in part on the colorcharacteristic. The method may include comparing a predetermined colorcharacteristic to color characteristics of a plurality of slab imagefiles stored in a database. The method may include responding to arequest from the remote party for a stone slab having a predeterminedcharacteristic. The stone slab may be a synthetic molded stone slabcomprising a quartz material. The image may have a length greater than9000 pixels. The image may have a length greater than 12000 pixels. Thedimensional relationship may include a length ratio (L_(slab)/L_(image))of slab length (L_(slab)) to image length (L_(image)), and the lengthratio (L_(slab)/L_(image)) is less than 0.02 in. per pixel. The lengthratio (L_(slab)/L_(image)) of slab length (L_(slab)) to image length(L_(image)) may be substantially the same at a peripheral edge of theslab and at a middle of the slab. The color characteristic of the imagemetadata may include a color rating. The image metadata may include acolor characteristic unique to the associated stone slab. The imagemetadata may include a dimension of the associated stone slab. Theremote party may be a countertop fabricator. Providing the slab imagefile associated with the stone slab to a remote party may occur beforeproviding the stone slab to the remote party, after providing the stoneslab to the remote party, or together with the stone slab such that theremote party receives the slab image file and the stone slab together.

Some embodiments described herein include an exemplary system formanufacturing and distributing stone slabs and corresponding images ofthe stone slabs. The system may include an inventory of stone slabs, anda database storing slab image files graphically representing the stoneslabs in the inventory. In a preferred option, the slab image files aregenerated at a stone slab manufacturing site. At least a first portionof the slab image files represent a corresponding first portion of theinventory of the stone slabs, and the first portion of the slab imagefiles may be remotely accessible by a remote user prior to thecorresponding first portion of the inventory of stone slabs beingaccessible to the remote user.

In some implementations, the system can optionally include one or moreof the following features. Preferably, each slab image file maygraphically represent a major surface of a corresponding stone slab inthe inventory of stone slabs, and each slab image file may include imagemetadata selected from the group consisting of an identifier thatspecifically identifies the corresponding stone slab, manufacturinginformation for the corresponding stone slab, a weight of thecorresponding stone slab, material information for the correspondingstone slab, at least one color characteristic of the corresponding stoneslab, and at least one dimensional characteristic of the correspondingstone slab. The dimensional characteristic of the corresponding stoneslab may include a dimensional relationship comprising a length ratio(L_(slab)/L_(image)) of slab length (L_(slab)) to image length(L_(image)), and the length ratio (L_(slab)/L_(image)) is less than 0.4mm per pixel. Optionally, the system may include an image generatorstation at the stone slab manufacturing site to generate the slab imagefiles when the stone slabs are manufactured.

In some embodiments, a method of manufacturing and distributing stoneslabs and corresponding images of the stone slabs may includemanufacturing a plurality of synthetic molded stone slabs according to apredetermined pattern such that each of the plurality of syntheticmolded stone slabs exhibit a similar visual appearance. The method mayfurther include assigning a unique identifier associated with each ofthe plurality of stone slabs, assigning a first subset of the pluralityof stone slabs to a remote party. Also, the method may include providingslab image files associated with each of the stone slabs to the remoteparty, and the slab image files may optionally include a medium formatimage of the stone slab and image metadata indicative of characteristicsof respective stone slabs. The image metadata may include, for example,the unique identifier, a color characteristic of the image (whichoptionally may be characterized as a numeric value), and a predetermineddimensional relationship including a ratio of stone slab unit length perimage pixel that is substantially consistent at any location of theimage. The step of assigning the first subset of the plurality of stoneslabs to the remote party may include comparing the color characteristicto color characteristics of a plurality of slab image files stored in adatabase. In some implementations, the step of assigning the stone slabto a remote party may occur before the step of providing the images andmetadata to the remote party.

In various embodiments, a method of manufacturing and managing stoneslabs may include manufacturing a plurality of synthetic molded stoneslabs according to a predetermined pattern, and receiving a request froma remote party for a stone slab having the predetermined pattern and acharacteristic. The method may also include identifying a stone slabhaving the predetermined pattern and characteristic by comparing slabimage files associated with an inventory of stone slabs to thecharacteristic, and responding to the request by delivering theidentified slab image file and associated stone slab.

In some implementations, the method can optionally include one or moreof the following features. The step of receiving the request from theremote party having the predetermined pattern and characteristic mayinclude receiving a unique identifier associated with a stone slab.Also, the step of receiving the request from the remote party mayinclude receiving a color characteristic (which may optionally be anumeric color rating).

In some embodiments, a system for manufacturing and distributing stoneslabs and corresponding images of the stone slabs may include aninventory of stone slabs assigned to a remote party. The system may alsoinclude a database storing at least a portion of stone slab image filesgenerated during manufacture of the inventory of stone slabs.Optionally, at least a portion of the stone slab image files areaccessible by the remote party before the inventory of stone slabs areaccessible by the remote party.

In some implementations, the system can optionally include one or moreof the following features. The stone slab image files may include imagemetadata indicative of characteristics of the stone slab. The slab imagefile may include a unique identifier and a predetermined dimensionalrelationship including a ratio of stone slab unit length per imagepixel, the ratio substantially consistent at any location of the image.The dimensional relationship may include a length ratio(L_(slab)/L_(image)) of slab length (L_(slab)) to image length(L_(image)), and the length ratio (L_(slab)/L_(image)) is less than 0.02in. per pixel.

Some embodiments described herein include a system for manufacturing anddistributing stone slabs and corresponding images of the stone slabs.The system may include means for manufacturing a stone slab to producean inventory of stone slabs, and means for generating stone slab imagefiles of the inventory of stone slabs. Optionally, the system mayinclude means for providing the stone slab image files to a remote partybefore the stone slabs are accessible by the remote party. The stoneslab image files may include image metadata indicative ofcharacteristics of the stone slab. For example, the image metadata mayinclude a unique identifier and a predetermined dimensional relationshipincluding a ratio of stone slab unit length per image pixel, the ratiosubstantially consistent at any location of the image. The dimensionalrelationship may include a length ratio (L_(slab)/L_(image)) of slablength (L_(slab)) to image length (L_(image)), and the length ratio(L_(slab)/L_(image)) is less than 0.4 mm per pixel.

Particular embodiments described herein include a system formanufacturing and distributing stone slabs and corresponding images ofthe stone slabs, The system may include an inventory of stone slabs, anda repository that stores at least a portion of stone slab image filesgenerated when the stone slabs are manufactured and associated with theinventory of stone slabs. Optionally, the stone slab image files mayinclude image metadata indicative of characteristics of the stone slab.

The systems and techniques described herein may provide one or more ofthe following advantages. First, some embodiments described hereininclude a system that generates images of stone slabs at a manufacturinglocation in a manner that can reduce costs and improve efficiencyassociated with quality control, distribution, fabrication/stonecutting, and other subsequent processes. Optionally, the system cangenerate and store digital images along with a set of additionallyuseful data as stone slabs move through an existing manufacturing linewithout a significant impact on the equipment and handling of the stoneslabs. In another example, the system can generate and store digitalimages for subsequent use in quality control activities, matching orgrouping of multiple stone slabs for shipment together, nesting orlayout design activities by a fabricator, and/or other activitiesthroughout the life of the stone slab.

Second, in some embodiments of the system described herein, a particularstone slab and a corresponding image (optionally, with its embeddedmetadata for the particular slab) may be associated with one another forthe entire life of the stone slab from initial manufacture to end-useinstallation, increasing the number of operations in which an image (andits embedded metadata for the particular slab) can replace or enhancephysical manipulation or inspection of a stone slab.

Third, in particular embodiments described below, a precise dimensionalrelationship between a stone slab and an associated image can becalculated and stored, for example, to facilitate reliable nestingoperations and may reduce measuring or other manipulation of thephysical stone slab. Further, multiple nesting and cutting operations ofa single slab may be carried out using a single image generated at atime of manufacture, providing benefits in inventory management andother operations even after a portion of the stone slab has been cut orremoved for a particular project. The image may be used to identify ormatch the remaining slab portion without requiring physical handling oradditional imaging of the remaining slab portion.

Fourth, some embodiments described herein include a system that alsogenerates image metadata associated with a stone slab that providesinformation, which may optionally allow an inventory of numerous stoneslabs to be readily searched and cataloged without physically handlingor moving the actual stone slabs. Additionally, one or more imagecharacteristics stored as part of the image metadata may be used togroup stone slabs for a particular customer or project, or to identify aparticular slab from an inventory of stone slabs. Accordingly, providingeach stone slab and its corresponding image (with its embedded metadatafor the particular slab) provides the capabilities for additionalautomation of such tasks and enhances reliability in matching andselecting of a stone slab having the characteristics called for by aparticular application.

The details of one or more implementations are set forth in theaccompanying drawings and the description below. Other features andadvantages will be apparent from the description and drawings, and fromthe claims.

DESCRIPTION OF DRAWINGS

FIG. 1 is a diagram of an exemplary system used in providing stone slabsand corresponding image files of the slabs.

FIG. 2 is a diagram of an exemplary system of manufacturing syntheticmolded stone slabs and generating corresponding image files of theslabs.

FIG. 3 is a diagram of an exemplary stone slab and associated imagefile.

FIG. 4 is a flow diagram of an exemplary process of providing stoneslabs and corresponding image files of the slabs.

FIG. 5 is a flow diagram of an exemplary process of identifying stoneslabs using an image file.

FIG. 6 is a flow diagram of an exemplary process of receiving and usingan image file of a stone slab and the corresponding stone slab.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Referring to FIG. 1, an exemplary system 100 can be used to produce oneor more stone slabs 50 and slab image files 120 associated with eachstone slab 50. In this embodiment, system 100 generates a highresolution image of stone slabs 50 such that the images are availablefor use in one or more subsequent operations throughout the life of thestone slabs 50.

In an exemplary embodiment, system 100 includes a manufacturing line 110including one or more stations for manufacturing stone slab 50. Forexample, stone slab 50 may be a synthetic molded stone slab comprising aquartz material and/or other particulate mineral material that, whenmixed with pigments and a resin binder and compressed, provides ahardened slab product suitable for use in living or working spaces(e.g., along a countertop, table, floor, or the like). Manufacturingstone slab 50 may include steps of dispensing one or more particulatemineral mixes in a mold, vibrating and/or compacting the particulatemineral mixes, curing the compacted mix, polishing a major surface,and/or other operations. In other exemplary embodiments, stone slab 50be may a quarried natural stone slab, and manufacturing line 110 mayinclude one or more cutting, polishing and/or other operations that canbe used to manufacture stone slab 50.

Stone slab 50 may be molded and/or cut to have a length L and a width W,as desired for a particular application. For example, stone slab 50 maybe a relatively large slab that may be cut to specific shapes for use inliving or working spaces (e.g., along a countertop, table, floor, or thelike). In various exemplary embodiments, stone slab 50 is at least 3feet wide by at least 6 feet long, for example between about 3 feet and8 feet wide and between about 6 feet and 14 feet long, or between about4.5 feet and 7 feet wide and between about 10 feet and 12 feet long. Insome exemplary embodiments, stone slab 50 is about 7 feet wide by about12 feet long. In other embodiments, stone slab 50 is preferably about4.5 feet wide (approximately 140 cm wide) by about 10 feet long(approximately 310 cm long). In some exemplary embodiments, stone slab50 may have an aesthetic effect including veins 51 and 52 that extendpartly or fully across a complete length L of the stone slab 50, throughthe thickness T of stone slab 50, and/or positioned relative to oneanother based on a predetermined pattern. Such characteristics mayprovide a natural vein appearance even when the slab is cut and edged tospecific shapes.

Stone slab 50 may proceed to an image generator station 115 resulting ina high resolution slab image file 120 of stone slab 50. In an exemplaryembodiment, the image generator station 115 includes a camera (e.g.,optionally, a “medium format” camera) mounted within an enclosure. Stoneslabs 50 may sequentially pass into the enclosure and within the fieldof view of the camera to be imaged.

In some exemplary embodiments, a slab image file 120 includes asubstantially distortion free image 121 and image metadata 125associated with image 121. In embodiments in which image generatorstation 115 includes a medium format camera, image 121 may be a mediumformat image. Also in this exemplary embodiment, the image generatorstation 115 is present at the same manufacturing location and/or processas an initial stone slab 50 polishing station and/or other manufacturingsteps. In some embodiments, the image generator station 115 ispositioned after a polishing station in system 100 and prior to storingthe slab for an inventory or for distribution to an offsite location. Inthis way, the high resolution slab image file 120 provides an electronicimage 121 of stone slab 50 at the time that stone slab 50 ismanufactured. In such embodiments, additional manipulation or physicalmovement of stone slab 50 can be reduced, and stone slab 50 is able tomove through manufacturing line 110, including an image generatorstation 115, as part of a streamlined system 100. Image 121 and/or otherinformation provided by slab image file 120 may then be used tofacilitate and/or automate one or more inventory management,distribution, fabrication or other operations throughout the life ofstone slab 50.

In an exemplary embodiment, image 121 provides a high resolution imagethat allows humanly perceptible characteristics of a physical stone slab50 to similarly be observed in image 121. In various exemplaryembodiments, image 121 may exhibit between about 25 megapixels and 500megapixels, 30 megapixels and 200 megapixels, or about 40 megapixels.Image 121 may thus be used in addition, and/or as a substitute, toviewing the physical stone slab 50. Slab image file 120 may be providedas any file or file set including the image 121 and image metadata 125.(As used herein, the term “high resolution image” means a digital imageof a slab having a resolution of 25 megapixels or greater. As describedin more detail below, other (lower) types of resolution are alsocontemplated in some embodiments described herein.)

System 100 further includes, in addition to or together with the imagegenerator station 115, a metadata generator station that generatesmetadata 125 associated with stone slab 50 and/or one or more images ofstone slab 50. For example, the metadata 125 may include informationrelated to stone slab 50 and/or slab image file 120 and may be generatedbefore, after, during, or as part of, an image generator station 115. Invarious exemplary embodiments, metadata 125 may include informationrelated to image 121 such as a unique identifier associating slab imagefile 120 with a particular stone slab 50, manufacturing information suchas a time and location of manufacture, characteristics of stone slab 50such as dimensional information, weight, materials, presence and/orlocation of imperfections, one or more color characteristics, includinga color characteristic that may uniquely identify a particular stoneslab 50, and/or a dimensional relationship between stone slab 50 and theassociated image, as described in greater detail herein.

System 100 further includes one or more databases 130 storinginformation related to system 100. Slab image files 120 associated withstone slabs 50 and generated at an image generator station may be storedin database 130 for subsequent access, use, modification and/ordistribution. For example, database 130 may include a data storagesystem made up of one or more repositories that together storeinformation related to system 100. Database 130 may include one or morelocal databases, for example housed locally at the manufacturinglocation, and/or may include one or more remote databases.

In an exemplary embodiment, database 130 includes a cloud-based systemthat may be accessed remotely, and access to various components ofdatabase 130 selectively granted to particular users. A manufacturerand/or system administrator may have complete access to all aspects ofdatabase 130, while a remote party may be granted access only toparticular content, such as particular slab image files 120 the remoteparty has purchased or is considering purchasing, for example.

In some exemplary embodiments, all or portions of slab image file 120and/or metadata 125 are stored as read-only data. Such information maybe permanently associated with a particular stone slab 50. For example,a unique identifier, manufacturing time, dimensional relationship(s),and/or color characteristics may be stored as read-only data. Otherinformation, such as a purchaser of stone slab 50 and/or otherinformation may be readily updateable throughout the life of slab imagefile 120, and may be selectable such that certain metadata may beincluded and/or viewable only by a particular user.

In addition to slab image files 120, database 130 may store other stoneslab information 132 and/or distribution information 133 related to oneor more remote parties. Such information may similarly be used for oneor more operations related to stone slabs 50 and/or selectivelydistributed to one or more users.

Still referring to FIG. 1, stone slabs 50 and one or more associatedslab image files 120 may subsequently be distributed to a remote party140. For example, in a distribution operation, particular stone slabs 50and associated slab image files 120 are assigned to remote party 140.Remote party 140 may be a purchaser of one or more stone slabs 50, or aprospective purchaser considering purchasing one or more stone slabs 50.In an exemplary embodiment, remote party 140 is a countertop fabricatorthat designs, cuts, and/or installs countertops in an end-useapplication at one or more locations remote from a manufacturinglocation of stone slab 50. In other exemplary embodiments, remote party140 may be a distributor, end user, or other member of a distributionchain.

Distribution of slab image files 120 from a location of manufacturingline 110 thus allows remote party 140 to receive stone slabs 50 and slabimage files 120 independent of one another. One or more stone slabs 50may be delivered to remote party 140 before, after or simultaneouslywith associated slab image files 120. For example, in an exemplarydistribution operation, slab image files 120 associated with stone slabs50 assigned to remote party 140 are provided to remote party 140 beforestone slabs 50 are physically provided to the remote party 140. Remoteparty 140 may review and/or use slab image files 120 for distribution,modeling, cutting or other operations in a time period that is hours,days or weeks in advance of physically receiving, handling and/orstoring stone slab 50. In this way, remote party 140 may beginpreparatory operations for a particular installation, for example, atleast partly independent of stone slab 50. Upon receipt by remote party140, stone slab 50 may be immediately cut and/or installed at a locationof end-use based on plans created using slab image file 120. Storagetime and handling by remote party 140 may thus be reduced, facilitatingefficiency and reducing an inventory held by remote party 140.

Alternatively or in addition, slab image files 120 may be provided forreview by remote party 140 before associated stone slabs are shipped.Remote party 140 may review and confirm or terminate shipment based atleast in part, and/or solely, on slab image files 120. In this way,physical handling and other costs associated with denied or returnedshipments may be further reduced.

In some exemplary embodiments, one or more associated stone slabs 50 andslab image files 120 may be provided together. For example, slab imagefiles 120 may be physically delivered on a storage device with stoneslabs 150. Slab image files 120 can immediately be used by the remoteparty in stone slab management, cutting, and/or other operations withoutfurther need to create an image or other catalog of the received stoneslabs 50 at the remote party location. Cost and floor space otherwiserequired by an image generator station may thus be omitted and dedicatedto other stations of remote party 140.

Referring to FIG. 2, an exemplary system 200 is shown that can be usedto manufacture and manage an inventory of synthetic molded stone slabs206. The synthetic molded stone slabs 206 may be imaged beforedistribution from the manufacturing location, as described above withsystem 100, for example, to generate an image file and metadataincluding information about an associated stone slab. Each of thesynthetic molded stone slabs 206 may include a quartz material and/orother particulate mineral material that, when mixed with pigments and aresin binder and compressed, provides a hardened slab product suitablefor use in living or working spaces.

In the exemplary system shown in FIG. 2, pigmented particulate mineralmixes are poured into a mold to generate a slab having a desiredaesthetic appearance. For example, stone slabs may be formed from twodifferently pigmented particulate mineral mixes that are poured intodifferent, designated regions of a respective mold. These designatedregions are repeated for each mold in a series of molds using, forexample, a set of stencil structures that can be positioned over eachmold and that provide a predefined complementary and repeatabledispensation pattern for the differently pigmented particulate mineralmixes. In some exemplary embodiments, the predefined complementary andrepeatable dispensation pattern for the differently pigmentedparticulate mineral mixes provides selected striations and veiningpatterns that are generally repeatable and that may result in a set ofstone slabs have a similar appearance.

The different mixes used to form the stone slabs can include organicpolymer(s) and an inorganic (mineral) particulate component. Theinorganic (mineral) particulate component may include such components assilicon, basalt, glass, diamond, rocks, pebbles, shells, a variety ofquartz containing materials, such as, for example, but not limited to:crushed quartz, sand, quartz particles, and the like, or any combinationthereof. In some embodiments, one or more particulate mineral mixes eachcomprise a quartz material as a predominant component, which may includesand of various particle sizes and of different combinations. In theresulting stone slab, the organic and inorganic materials can be linkedusing a binder, which may include for example, mono-functional ormultifunctional silane molecules, dendrimeric molecules, and the like,that may have the ability to bind the organic and inorganic componentsof the composite stone mix. The binders may further include a mixture ofvarious components, such as initiators, hardeners, catalysators, bindingmolecules and bridges, or any combination thereof. Some or all of themixes dispensed in the mold may include components that are combined ina mixing apparatus (not shown) prior to being conveyed to the mold. Themixing apparatus can be used to blend raw material (such as the quartzmaterial, organic polymers, unsaturated polymers, and the like) atvarious ratios. For example, some or all of the mixes dispensed in themold may include about 8-95% quartz aggregates to about 5-15% polymerresins. In addition, various additives, may be added to the rawmaterials in the mixing apparatus, such additives may include, metallicpieces (e.g., copper flecks or the like), colorants, dyes, pigments,chemical reagents, antimicrobial substances, fungicidal agents, and thelike, or any combination thereof.

Still referring to the embodiment shown in FIG. 2, system 200 forforming a set of synthetic molded stone slabs sequentially dispenses oneor more of the differently pigmented particulate mineral mixes into amold which is then processed using a subsequent compression moldingoperation (e.g., vibro-compaction molding, curing, etc.). First, acollection of slab molds 203 are transported on an input conveyor 201 toan air table. The air table includes a collection of outlets formed on atop surface with air pumped through the outlets to form a cushion of airbetween the top surface and slab molds 203, to help operators moveand/or orient slab molds 203.

Slab molds 203 proceed to one or more mineral aggregate distributors204, which receives one or more particulate mineral mixes fromcorresponding mixers 205. In an exemplary embodiment, each of themineral aggregate distributors 204 includes a dispensing head and isconfigured to reciprocate over the mold 203 as the dispenser headreleases a selected particulate mineral mix into the mold 203 (or isotherwise configured to deposit the selected particulate mineral mixinto the mold 203). Dispensing heads may each be configured with ashutter or valve apparatus (not shown in FIG. 2) that is controllable toregulate the flow of particulate mineral mix from dispensing head toslab mold 203 and that is controllable to dispense material into slabmolds 203 at a substantially repeatable rate.

After slab mold 203 has been sufficiently filled, slab mold 203 (now afilled mold 206) is moved to an output conveyor 202. Output conveyor 202can be configured to transport each of the filled molds 200 to one ormore subsequent stations in system 200. For example, each of filledmolds 206 can continue to a subsequent station in which a top moldattachment 207 is positioned over the filled mold 206 so as to encasethe layers of particular mineral mixes between the mold 203 and a topcover mold piece (not shown in FIG. 2). From there, the filled mold 206including the top cover mold piece continues to a subsequent station inwhich a vibro-compaction press 208 applies compaction pressure,vibration, and vacuum to the contents inside the filled mold 206,thereby converting the one or more particulate mixes into a rigid slab.After the vibro-compaction operation, filled mold 206 (with thecompacted and hardened slab therein) proceeds to a curing station 209 inwhich the material used to form the slab (including any resin bindermaterial) are cured via a heating or other curing process, therebyfurther strengthening the slab inside the filled mold 206. After theslab is fully cured and sufficiently cooled, primary mold 203 and thetop mold cover piece are removed from the hardened and cured slab at amold removal station 211. Primary mold 203 is returned to the inputconveyor 201. The hardened and cured slab is moved to a polisher station212, in which a major surface of the slab is polished to a smooth finishproviding an appearance having, for example, complex striations andveining patterns. In such circumstances, the polished major surface ofeach of synthetic molded slabs provides an outer appearance that isgenerally repeatable and similar to the other slabs (e.g. from otherfilled molds 208 in FIG. 2).

In an exemplary embodiment, system 200 includes an image generatorstation 270 that can be used to generate an image associated with eachstone slab manufactured by system 200. Image generating station 270 maybe positioned after polisher station 212 such that a polished slab canreadily proceed to image generating station 270. In an exemplaryembodiment, image generating station 270 generates a high resolution,medium format image associated with each stone slab. As described abovewith reference to FIG. 1, the resulting images may be stored as imagefiles including associated metadata that may be used in inventorymanagement, quality assurance, stone slab selection and matching, andfabrication operations, for example, as described in greater detailherein.

Referring to FIG. 3, an exemplary stone slab 350 and associated slabimage file 320 are shown. Stone slab 350 may be a synthetic manufacturedstone slab, quarried slab or other stone slab 350, and associated slabimage file 320 provides a high resolution image 321 and image metadata325 related to stone slab 350. Stone slab 350 exhibits a variety offeatures and characteristics, for example resulting from a manufacturingprocess, and slab image file 320 may include a substantially distortionfree, high resolution, medium format image 321 and image metadatarelated to such features and characteristics.

As described above regarding system 100, image metadata 325 may includedata related to stone slab 350 such as, for example, a unique identifierassociating slab image file 320 with a particular stone slab 350, timeand location of manufacture, dimensional information, weight, presenceand/or location of imperfections, one or more color characteristics,and/or other data.

In an exemplary embodiment, image metadata 325 includes a uniqueidentifier that allows association between a particular stone slab 350and an associated slab image file 320. The unique identifier may includea unique number, code or other identifier that uniquely identifies asingle stone slab 350 from one or more other stone slabs 350.

Stone slab 350 is tagged with the unique identifier and/or additionalinformation related to stone slab 350. In an exemplary embodiment, alabel 355 is provided on stone slab 350 that includes the uniqueidentifier in a computer-readable and/or human readable format. Thelabel may include a barcode, RFID tag, QR code, etching or writingdirectly on the stone slab, and/or other identifier. In some exemplaryembodiments, the label may be an RFID tag that is embedded in the stoneslab such that the tag is not visually perceptible (e.g. when stone slabis installed) but may communicate the unique identifier and/or otherinformation when interacted with by an appropriate reader, such as ascanner or RFID tag reader. The unique identifier may be used throughoutthe life of the associated stone slab to associate the stone slab withan image and/or other information related to stone slab 50.

Still referring to FIG. 3, stone slab 350 and image 321 may exhibit adimensional relationship such that image 321 and/or metadata 325provides accurate information related to one or more dimensionalcharacteristics of stone slab 350. In an exemplary embodiment, stoneslab 350 exhibits various dimensions including a width W and Length Lresulting from a molding and/or cutting operation. Stone slab 350 mayalso have an aesthetic effect such as veins 351 and 352 that extendpartly or fully across a complete length L of stone slab 350 that may becharacterized by particular dimensions and spacing. For example, suchaesthetic effects may be positioned relative to one another based on apredetermined pattern, and may be similar among a set of stone slabs350.

Image 321 provides a dimensionally accurate representation of stone slab350 that both accurately represents relative positioning of edges, veinsand/or other features within the slab image, and allows accuratedetermination of absolute distances between edges and/or such features.Such dimensional accuracy allows image 321 to be used in selecting andmatching operations, and in nesting operations in which stone slab 350is divided into portions having desired sizes and characteristics for aparticular installation. For example, image 321 may be substantiallydistortion free such that relative positioning of various aestheticfeatures depicted by image 321 is consistent with stone slab 350.

In an exemplary embodiment, one or more images 321 have a predetermineddimensional relationship with stone slabs 350, such as a consistentratio of stone slab unit length per image pixel. For example, one ormore images 321 may exhibit a ratio of stone slab unit length per imagepixel having a desired value. In various exemplary embodiments, a lengthratio (L_(slab)/L_(image)) of slab length (L_(slab)) to image length(L_(image)) may be less than 0.02 in. per pixel, less than 0.018 in. perpixel, less than 0.016 in. per pixel, less than 0.014 in. per pixel,less than 0.012 in. per pixel, or less than 0.01 in. per pixel. Forexample, a length ratio of (L_(slab)/L_(image)) may be between 0.005 in.per pixel to 0.02 in. per pixel, 0.01 in. per pixel to 0.018 in. perpixel, or about 0.014 in. per pixel.

In an exemplary embodiment, image 321 is substantially distortion freesuch that the length ratio (L_(slab)/L_(image)) of unit slab length toimage length is substantially consistent at any location of image 321.For example, a particular length of image 321 corresponds to aconsistent length of stone slab 350, irrespective of whether the lengthis at a peripheral edge, middle, or other location of image 321. Image321 thus provides a reliable tool for measuring and cutting stone slab350. Nesting layouts in which veins, coloring and/or imperfections areintended to be included or avoided in a cut portion or seam, forexample, can be prepared using image 321 and reliably applied to stoneslab 350.

Furthermore, such dimensional accuracy allows image 321 to be reusedthrough the life of any remaining portion of stone slab 350. Forexample, after stone slab 350 is cut to remove a portion having adesired size, dimensions of the removed portion and/or remaining slabmay be accurately depicted using image 321. Image 321 can thus be reusedin subsequent cutting or other operations without a need to generate anew image from the physical partial slab.

In an exemplary embodiment, image metadata 325 includes dimensionalinformation related to stone slab 350 described above. For example,image metadata 325 may include width, length, thickness and/or otherdimensions of stone slab 350, width, length, thickness and/or otherdimensions of image 321, and/or one or more further dimensionalrelationships between stone slab 350 and image 321, such as the lengthratio (L_(slab)/L_(image)) of slab length (L_(slab)) to image length(L_(image)). Image 321 and image metadata 325 including dimensionalinformation may thus be used together in one or more operations of stoneslab 350. A high degree of dimensional accuracy and a predetermineddimensional relationship between image 321 and stone slab 350 allowstone slab to be accurately mapped and cut. Nesting and/or otheroperations may thus be performed with limited or no physical referenceto stone slab 350.

Still referring to FIG. 3, image 321 and metadata 325 of slab image file320 include information related to one or more color characteristics ofassociated stone slab 350. The visual appearance of stone lab 350 isaffected significantly by the colors of its major surfaces, andparticularly the colors of one or more veins, patterns, or otherfeatures. Color thus plays a major role in the aesthetic impressionstone slab 350 provides to a viewer, and affects how portions ofmultiple stone slabs 350 may be suitably grouped, positioned, and/orseamed, for example, when one or more stone slabs 350 are prepared forinstallation. In an exemplary embodiment, image 321 provides an accuratecolor representation of such features of stone slab 350, and imagemetadata 325 includes information related to one or more colorcharacteristics of stone slab 350.

In various exemplary embodiments, image metadata 325 may include one ormore color characteristics related to a color of stone slab 350. Forexample, image metadata 325 may include a color characteristic includinga numeric value representative of one or more of color intensity,uniformity and/or tonality. A color characteristic including a numericvalue may be generated using a color measurement and analysis technique.In an exemplary embodiment, a numeric value is generated using L*a*b*values. For example, L*a*b* values may be generated for some or alllocations and/or pixels of slab image 121 to provide an indicator ofvarious color characteristics of stone slab 50, including veining, flow,movement, distribution of particulate material, etc. useful insubsequent operations related to stone slab 50.

In an exemplary embodiment, image metadata 325 may include a numericcolor characteristic based at least in part on color characteristicsassociated with one or more regions of slab image 321. For example, slabimage 321 may be divided into imaginary regions (such as an array/matrixof regions (a), (b), etc.), and numeric color values generated for eachregion. Image metadata 325 may thus include one or morelocation-specific color characteristics, in addition to one or morevalues representative of an overall color characteristic of stone slab350.

Alternatively or in addition, image metadata 325 may include one or morenumeric color characteristic values, such as a slab color rating,representative of an overall color characteristic of stone slab 350and/or a combination of local color characteristic values. For example,image metadata 325 may provide a numeric color rating that provides anoverall indicator of color and that may be compared to color ratingsassociated with other stone slabs 350. That is, an exemplary numericcolor rating may provide an indicator of how a particular stone slab 350appears as compared to other stone slabs 350 having a similar styleand/or predetermined pattern. Accordingly, a set of stone slabs 350 of aparticular style having similar color ratings may be characterized ashaving a similar visual color appearance, while stone slabs 350 of aparticular style having different color ratings may be characterized asexhibiting relatively different visual appearances. In this way, asingle numeric color characteristic value included as image metadata325, alone or in combination with one or more items of information ofslab image file 320, may be used to quickly qualify, group, match,and/or select a specific stone slabs 50.

In some embodiments, image metadata 325 may include one or more colorcharacteristic values that are unique to image 321 and/or associatedstone slab 350. That is, an exemplary color characteristic may result ina numeric value or array of values representative of color values at oneor more locations of stone slab 350 that provides a unique colorsignature. For example, a unique numeric value may result from compilingcolor characteristics at various locations of slab image 321 to provideboth color information useful in subsequent operations and a numericvalue that uniquely identifies stone slab 350 based on colorcharacteristics of that particular stone slab 350.

In various exemplary embodiments, image metadata 325 may includeadditional information related to an appearance of stone slab 350. Forexample, image metadata 325 may include one or more defect identifiersproviding a location and/or other information regarding one or moredefects. Alternatively or in addition, image metadata 325 may includeinformation related to surface properties of stone slab 350, such asinformation related to surface polish, scratches, gloss, etc. In someexemplary embodiments, image metadata 325 includes gloss values acrossstone slab 350 that may be used to determine appropriate seam placement.

Referring to FIG. 4, a flow diagram of an exemplary process 400 formanufacturing and managing a stone slab is shown, including providing aslab image file generated at a manufacturing location to a remote partyfor use in one or more operations related to the stone slab. In anexemplary embodiment, process 400 first includes operation 402 ofmanufacturing the stone slab, such as stone slab 50 described herein.Manufacturing the stone slab may include steps of dispensing one or moreparticulate mineral mixes in a mold, vibrating and/or compacting theparticulate mineral mixes, curing the compacted mix, and/or polishing amajor surface of the resulting stone slab. Alternatively, the stone slabmay be a quarried natural stone slab that is cut and/or polished duringoperation 402.

Process 400 further includes operation 404 of assigning a uniqueidentifier associated with the stone slab. The unique identifier mayinclude a unique number, code or other identifier that uniquelyidentifies a single stone slab from one or more other stone slabs. Insome exemplary embodiments, operation 404 of assigning a uniqueidentifier may include tagging the stone slab with the uniqueidentifier, for example by affixing a label, barcode, tag, etching orwriting on the stone slab, or other technique.

In an exemplary embodiment, process 400 includes operation 406 ofgenerating a slab image file associated with the stone slab manufacturedin manufacturing operation 402. As described herein, operation 406 mayinclude generating a high resolution image, such as a high resolution“medium format” image, for example, of the stone slab and/or generatingimage metadata including information related to the stone slab andimage. In an exemplary embodiment, operation 406 of generating a slabimage file is performed at the same location, and in some embodiments,at the same manufacturing line, as operation 402 of manufacturing thestone slab. For example, a stone slab may proceed from a polishing lineto an image generator, as described above with reference to system 100,such that less physical handling and other manipulation is required toposition the stone slab for imaging.

Exemplary process 400 further includes operation 408 of storing a slabimage file in a database. For example, one or more slab image filesgenerated in operation 406 may be transferred to or otherwise stored ina database for subsequent access, use, modification and/or distribution.Operation 408 may include steps of storing the slab image file to acloud-based database system and/or grouping the slab image filesaccording to one or more features and characteristics stored as imagemetadata.

In various exemplary embodiments, operation 406 of generating a slabimage file results in an image and image metadata associated with aparticular stone slab that can streamline and/or automate varioussubsequent operations before stone slabs are delivered to a remoteparty. For example, the slab image file may be used in operation 410 ofqualifying stone slabs produced during manufacturing operation 402.Qualifying operation 410 may include confirming the absence of defectsand/or ensuring features and characteristics of a stone slab are withina predetermined acceptable range using the slab image file generated inoperation 406. For example, one or more numeric dimensional, colorcharacteristic and/or other characteristics stored as image metadata maybe compared to a predetermined acceptable characteristic value or rangeof values, and the stone slab qualified and/or sorted for subsequentoperations based on the one or more numeric characteristics.

Operation 410 of qualifying a stone slab may further include grouping astone slab with one or more other stone slabs exhibiting similarfeatures and characteristics. For example, a stone slab having adimensional, color and/or other characteristic within a particular rangemay be assigned to a first group of stone slabs, and a stone slab havinga color characteristic value within a different range may be assigned toa second group of stone slabs. A slab image file storing the colorcharacteristic value thus allows grouping of stone slabs withoutextensive human review of either the physical stone slab or an image.Qualifying an inventory of stone slabs into one or more groups having asimilar characteristic facilitates efficient management and distributionof stone slabs, as described herein.

Still referring to FIG. 4, process 400 includes operation 412 ofassigning one or more stone slabs to a remote party. Stone slabs may beassigned in preparation of delivery and/or in response to an orderplacement or other request from a remote party. In an exemplaryembodiment, stone slabs are assigned to a remote party at least in partusing image metadata of a slab image file. For example, a set of stoneslabs may be assigned to the remote party from a set of stone slabspreviously grouped based on one or more characteristics stored as imagemetadata. Alternatively or in addition, the slab image file may be usedto identify a stone slab having a similar dimensional, color and/orother characteristic in response to a request for a particular style.Stone slabs having one or more similar characteristics may thus beidentified and assigned with little or no human review of the stone slabor image based at least in part on an image and/or metadata generated atthe location of manufacturing operation 402.

At operations 414 and 416, slab image files and associated stone slabsare provided to a remote party. Slab image files and stone slabs may beprovided to the remote party in any sequence. In an exemplaryembodiment, one or more slab image files are provided to a remote partyin advance of delivery of associated stone slabs. Accordingly, theremote party may review and/or use the slab image files while thephysical stone slab remains in a remote location. Further, the slabimage file may allow the remote party to confirm or cancel delivery,begin preparing layouts in a nesting operation, and/or make otherdecisions regarding associated stone slabs before stone slabs have lefta manufacturing or storage facility. Alternatively, or in addition, slabimage files and stone slabs may be provided to the remote partysubstantially simultaneously. When received by the remote party, afabrication operation, for example, may be initiated immediately byusing the associated slab image files, while additional processing stepsof inspecting, cataloging, and/or imaging the received stone slabs atthe remote party location are reduced.

Operation 414 of providing slab image files to a remote party mayinclude one or more steps of making slab image files available to aremote party. In an exemplary embodiment, providing slab image files toa remote party includes assigning an identifier, such as a customeridentifier, lot identifier, order identifier, etc. to one or more slabimage files associated with stone slabs to be provided to the remoteparty. Slab image files associated with the identifier may then bestored in a database or other repository accessible by the remote partyto view, download, use and/or otherwise access such slab image files. Inthis embodiment, slab image files are accessible by a particular remoteparty, and are not accessible by other remote parties to which the stoneslabs are not assigned. Slab image files of the actual stone slabs,rather than merely representative images, are thus made available to theremote party. Alternatively or in addition, associated slab image filesmay be directly transferred to the remote party, for example byelectronic distribution and/or physical delivery of a storage mediumcontaining the one or more slab image files.

Referring to FIG. 5, a flow diagram of an exemplary process ofdelivering a stone slab based on a request from a remote party is shown.Process 500 may include one or more steps related to providing a stoneslab to a remote party based at least in part on information stored in aslab image file. In this way, information obtained from a slab imagefile may be used to identify and provide stone slabs that exhibitparticular dimensional, color and/or other characteristics, in additionto a particular style and/or predetermined pattern.

In an exemplary embodiment, operation 504 includes receiving a requestfrom the remote party. Operation 504 of receiving a request may includereceiving a request for a matching stone slab and/or receiving one ormore items of information related to a requested dimensional, color, orother characteristic of a stone slab. In some exemplary embodiments,receiving the request may include receiving a unique identifier of astone slab previously provided to the remote party or in the remoteparty's existing inventory. The unique identifier may be used toidentify the previously delivered stone slab and its characteristics.Alternatively or in addition, receiving a request may include receivinga dimensional, color, and/or other characteristic to be matched, inaddition to a predetermined style or pattern of the stone slab.Accordingly, a remote party may request not only a stone slab having aparticular predetermined style or pattern, but also request a stone slabthat exhibits certain characteristics that closely match one or moreother stone slabs having the predetermined style or pattern.

At operation 508, one or more stone slabs having one or morecharacteristics consistent with the received request are identifiedusing slab image files associated with an inventory of stone slabs. Inan exemplary embodiment, operation 508 may include steps of identifyinga desired dimensional, color and/or other characteristic based at leastin part on the received request, comparing the characteristic to imagemetadata of an inventory of slab image files stored in a database, andidentifying one or more stone slabs that satisfy the received request.At operation 510, a response is provided to the remote party, and mayinclude steps of providing one or more slab image files and associatedstone slabs to the remote party, as described above regarding process400, for example.

In an exemplary embodiment, process 500 allows a manufacturer to providea customer or other party with multiple stone slabs having consistentdimensional, color and/or other characteristics. The remote party isable to receive one or more stone slabs that are highly compatible withone another and/or one or more stone slabs in its existing inventory.The remote party may thus be able to carry a relatively smallerinventory while being able to closely match stone slabs in fabricationoperations.

Referring to FIG. 6, an exemplary process 600 for receiving and using aslab image file by a remote party is shown. The remote party, such as acountertop fabricator, distributor, or the like, may receive and use oneor more slab image files as described herein to efficiently manage ashipment and/or inventory of one or more stone slabs. In an exemplaryembodiment, process 600 allows the remote party to receive and use oneor more slab image files before receiving associated stone slabs. Atoperation 602, a remote party receives a slab image file from a stoneslab manufacturer or distributor, for example, containing a highresolution and substantially distortion free image and image metadatarelated to an associated stone slab. The remote party thus receivesdetailed information regarding one or more stone slabs with reduced orno delivery costs and/or physical handling, and the information allowsinitiation of one or more operations before receiving associated stoneslabs.

For example, at operation 604, the remote party may perform one or moresteps related to confirming a stone slab shipment by reviewing the imageand/or image metadata. Operation 604 may include on or more steps ofconfirming the slab image files are associated with desired stone slabs,exhibit desired dimensional, color and/or other characteristics, arefree from defects, and/or are otherwise acceptable. In some exemplaryembodiments, the remote party may accept or decline delivery of one ormore stone slabs based on inspection of the slab image files, and insome exemplary processes, accept or decline delivery before the stoneslabs have left a manufacturing or distribution facility.

In various exemplary processes, the remote party may use one or moreslab image files received at operation 602 in one or more subsequentoperations before delivery of associated stone slabs. At operation 606,slab image file may be used in a nesting layout to divide associatedstone slabs into portions for a countertop or other installation, andthe operation may be reliably performed using the slab image filecontaining a substantially distortion free, high resolution image andimage metadata including one or more dimensional, color, or othercharacteristics. The slab image files thus allow such operations to becarried out before receiving the stone slab and while reducing floorspace and physical exertion associated with such operations.

In an exemplary embodiment, the remote party receives stone slab atoperation 608, which may immediately be cut and/or otherwise manipulatedat operation 610 based on preparations made during operation 606.Accordingly, some or all operations of the remote party may befacilitated using slab image files in advance of receiving associatedstone slabs. In various other exemplary embodiments, stone slab may bereceived together or in advance of an associated slab image file, andthe slab image file may be advantageously used when received in additionto or as an alternative to the stone slab.

While this specification contains many specific implementation details,these should not be construed as limitations on the scope of anyinvention or of what may be claimed, but rather as descriptions offeatures that may be specific to particular embodiments. Certainfeatures that are described in this specification in the context ofseparate embodiments can also be implemented in combination in a singleembodiment in part or in whole. Conversely, various features that aredescribed in the context of a single embodiment can also be implementedin multiple embodiments separately or in any subcombination. Moreover,although features may be described herein as acting in certaincombinations and/or initially claimed as such, one or more features froma claimed combination can in some cases be excised separate from thecombination, and the claimed combination may be directed to asubcombination or variation of a subcombination.

Similarly, while operations are depicted in the drawings in a particularorder, this should not be understood as requiring that such operationsbe performed in the particular order shown or in sequential order, orthat all illustrated operations be performed, to achieve desirableresults. Although a number of implementations have been described indetail above, other modifications are possible. For example, the logicflows depicted in the figures do not require the particular order shown,or sequential order, to achieve desirable results. In addition, othersteps may be provided, or steps may be eliminated, from the describedflows, and other components may be added to, or removed from, thedescribed systems. Accordingly, other implementations are within thescope of the following claims.

What is claimed is:
 1. A method of manufacturing and distributing stoneslabs and corresponding images of the stone slabs, comprising:manufacturing a synthetic molded stone slab; assigning a uniqueidentifier associated with the stone slab; and providing a slab imagefile associated with the stone slab to a remote party, the slab imagefile comprising a high resolution image of the stone slab and imagemetadata indicative of characteristics of the stone slab; wherein theimage metadata of the slab image file comprises the unique identifier, acolor characteristic, and a predetermined dimensional relationshipincluding a ratio of stone slab unit length per image pixel, the ratiosubstantially consistent at any location of the image; and wherein thecolor characteristic of the image metadata comprises a numeric colorrating.
 2. The method of claim 1, further comprising providing the stoneslab to the remote party.
 3. The method of claim 1, further comprisingstoring the slab image file in a database, and wherein the step ofproviding the slab image file to the remote party comprises granting theremote party access to the database.
 4. The method of claim 1, furthercomprising a step of assigning the stone slab to a remote party beforethe step of providing the slab image file to the remote party.
 5. Themethod of claim 4, wherein the step of assigning the stone slab to aremote party comprises assigning the stone slab based at least in parton the color characteristic.
 6. The method of claim 5, furthercomprising comparing a predetermined color characteristic to colorcharacteristics of a plurality of slab image files stored in a database.7. The method of claim 1, further comprising responding to a requestfrom the remote party for a stone slab having a predeterminedcharacteristic.
 8. The method of claim 1, wherein the stone slab is asynthetic molded stone slab comprising a quartz material.
 9. The methodof claim 1, wherein the image has a length greater than 9000 pixels. 10.The method of claim 1, wherein the image has a length greater than 12000pixels.
 11. A method of manufacturing and distributing stone slabs andcorresponding images of the stone slabs, comprising: manufacturing asynthetic molded stone slab; assigning a unique identifier associatedwith the stone slab; and providing a slab image file associated with thestone slab to a remote party, the slab image file comprising a highresolution image of the stone slab and image metadata indicative ofcharacteristics of the stone slab; wherein the image metadata of theslab image file comprises the unique identifier and a predetermineddimensional relationship including a ratio of stone slab unit length perimage pixel, the ratio substantially consistent at any location of theimage; wherein the dimensional relationship comprises a length ratio(L_(slab)/L_(image)) of slab length (L_(slab)) to image length(L_(image)), and the length ratio (L_(slab)/L_(image)) is less than 0.02in. per pixel.
 12. The method of claim 1, wherein a length ratio(L_(slab)/L_(image)) of slab length (L_(slab)) to image length(L_(image)) is substantially the same at a peripheral edge of the slaband at a middle of the slab.
 13. The method of claim 11, wherein theimage metadata includes a color characteristic of the stone slab, andthe color characteristic of the image metadata comprises a numeric colorrating.
 14. The method of claim 1, wherein the color characteristic isunique to the associated stone slab.
 15. The method of claim 1, whereinthe image metadata comprises a dimension of the associated stone slab.16. The method of claim 1, wherein the remote party is a countertopfabricator.
 17. The method of claim 2, wherein providing the slab imagefile associated with the stone slab to a remote party occurs beforeproviding the stone slab to the remote party.
 18. The method of claim 2,wherein providing the slab image file associated with the stone slab toa remote party occurs after providing the stone slab to the remoteparty.
 19. The method of claim 2, wherein the slab image file associatedwith the stone slab is provided together with the stone slab such thatthe remote party receives the slab image file and the stone slabtogether.
 20. A system for manufacturing and distributing syntheticmolded stone slabs and corresponding images of the stone slabs,comprising: an inventory of synthetic molded stone slabs; a databasestoring slab image files graphically representing the stone slabs in theinventory and being generated at a stone slab manufacturing site,wherein at least a first portion of the slab image files of the databasethat represent a corresponding first portion of the inventory of thestone slabs are remotely accessible by a remote user prior to thecorresponding first portion of the inventory of stone slabs beingaccessible to the remote user; wherein each slab image file graphicallyrepresents a major surface of a corresponding stone slab in theinventory of stone slabs, each slab image file comprising image metadataincluding at least one dimensional characteristic of the correspondingstone slab; and wherein the dimensional characteristic of thecorresponding stone slab includes a dimensional relationship comprisinga length ratio (L_(slab)/L_(image)) of slab length (L_(slab)) to imagelength (L_(image)), and the length ratio (L_(slab)/L_(image)) is lessthan 0.4 mm per pixel.
 21. The system of claim 20, wherein each slabimage file comprises image metadata including an identifier thatspecifically identifies the corresponding stone slab, manufacturinginformation for the corresponding stone slab, a weight of thecorresponding stone slab, material information for the correspondingstone slab, and at least one color characteristic of the correspondingstone slab.
 22. The system of claim 21, further comprising an imagegenerator station at the stone slab manufacturing site to generate theslab image files when the stone slabs are manufactured.
 23. A method ofmanufacturing and distributing stone slabs and corresponding images ofthe stone slabs, comprising: manufacturing a plurality of syntheticmolded stone slabs according to a predetermined pattern such that eachof the plurality of synthetic molded stone slabs exhibit a similarvisual appearance; assigning a unique identifier associated with each ofthe plurality of stone slabs; assigning a first subset of the pluralityof stone slabs to a remote party; and providing slab image filesassociated with each of the stone slabs to the remote party, the slabimage files comprising a medium format image of the stone slab and imagemetadata indicative of characteristics of respective stone slabs;wherein the image metadata comprises the unique identifier, a colorcharacteristic of the image, and a predetermined dimensionalrelationship including a ratio of stone slab unit length per image pixelthat is substantially consistent at any location of the image; andwherein assigning a first subset of the plurality of stone slabs to theremote party comprises comparing the color characteristic to colorcharacteristics of a plurality of slab image files stored in a database.24. The method of claim 23, wherein the step of assigning the stone slabto a remote party occurs before the step of providing the images andmetadata to the remote party.
 25. A method of manufacturing and managingstone slabs, comprising: manufacturing a plurality of synthetic moldedstone slabs according to a predetermined pattern; receiving a requestfrom a remote party for a stone slab having the predetermined patternand a characteristic; identifying a stone slab having the predeterminedpattern and characteristic by comparing slab image files associated withan inventory of stone slabs to the characteristic; responding to therequest by delivering the identified slab image file and associatedstone slab; wherein the step of receiving a request from a remote partyhaving a predetermined pattern and characteristic comprises receiving aunique identifier associated with a stone slab; and wherein the step ofreceiving a request from a remote party comprises receiving a colorcharacteristic including a numeric color rating.
 26. The method of claim25, wherein each slab image file comprises image metadata including atleast one dimensional characteristic of the corresponding stone slab,the dimensional characteristic of the corresponding stone slab includinga dimensional relationship comprising a length ratio(L_(slab)/L_(image)) of slab length (L_(slab)) to image length(L_(image)), and the length ratio (L_(slab)/L_(image)) is less than 0.4mm per pixel.